Manufacture of printed floor coverings



May l2, 1931o A. JoNl-:s 1,805,144

MANUFACTURE OF PRINTED FLOOR COVERVINGS Filed Aug.A 13 192e Patented May 12, 1931 'UNITED STATES PATENT OFFICE ALFRED JONES, OF LANCASTER, PENNSYLVANIA, ASSGNOR TO ARMSTRONG CORK COMPANY, F LANCASTER, PENNSYLVANIA, A CORPORATION, OF PENNSYLVANIA MANUFACTURE OF PRINTED FLOOR COVERINGS Application filed August 13, 1926. Serial No. 129,026.

This invention relates to the manufacture.

i of printed floor coverings, such as linoleum,

` blocks.

felt base Hoor coverings, and the like, the novel'iloor covering producedy by the practiceof the present invention comprising the subject matter of my copending application Serial No. 233,892 filed Nov. 17, 1927 According to the present practice of printingA the surfaceof linoleum rand other floor coverings, the various coldrs are successively applied to the surface ofthe floor covering by means of vertically reciprocal printing These printing blocks have a printing surface which is formed of a plurality of very small pegs, usually of wood, each peg being separated from /the adjacent ones. This is necessary in order to get a smooth distribution ofthe paint and allow for the escape of air when the printing block comes down on to the material and to allow air to enter under the block when the block raises from the printed surface.

Heretofore the usual slow drying oil paints have always been used in machines of this character as the coating material. Due to the fact that the paint is necessarily slow drying, a very large amount of curing space, or sto've room, is necessary for taking care l of the output of a single machine, as the freshly painted material must cure for several days before it can be further handled.

' Furthermore, any paint used on a floorcovering is subjected to the action of alkalies in soaps, and these alkalies are detrimental to ordinary oil base paints.

According to the present invention it is proposed to use a nitrocellulose lacquer as a vehicle. for the print paints, thus eliminating the use of linseed or other drying oils in order to produce a paint which is highly resistant to the action of alkalies and soaps commonly used for the cleaning of floor coverings.

, Fmthermore, nitrocellulose lacquers are quick drying, and consequently the material can be handled much more quickly after it has been printed, and the amount of storage or curing space necessary to take care of the out put of a single machine is materially reduced. There are several lacquer paints now on the market which can be applied with a brush or witha spray, but no lacquer paint has heretofore been produced which can be used on printing machines of the type used in the decorating of floor coverings. 'Ihe greatest diiculty, in connection with all of these paints up to the present time, is their tendency to set, due largely to the fact that they are quick drying, thereby choking up the printing blocks and preventing the machines from operating on a production basis.

It is proposed bythe present' invention to provide a method by means of which nitrocellulose lacquers commonly called lacquer paints can beL practically used with present types of printing machines without choking the printing blocks, and to produce a printed floor covering wherein the paint is highly resistant tothe action of alkalies. The present invention also contemplates the provisionof novel apparatus by means of which the invention can be most effectively and economically practiced.

The invention may be readily understood by reference to the accompanying drawings in which:

Figure. 1 is a diagrammatic vertical section taken longitudinally of a printing machine and curing stove;

Figure 2 is a perspective view showing a portion of one of the'printing blocks to illustrate the peg-likev structure of the printing surface.

In the drawings, 2 designates the bed of a standard type of printing machine and 3 are the vertically reciprocal printing blocks. These blocks have'a sawed or pegyllke printing surface 4, as clearly shown in Figure 2. By reference to Figure 2, it will be seen that the printing surface, which is of a divided nature projects beyond the general surface of the block, and it is to this portion of the block that the paint material is applied and it is this portion of the block thatengages drying. Provision is preferably made for heating the stoves or curing rooms 6, al though such means hasnot been shown in the drawings. Provision is made for withdrawing vapors from the steve in order to collect the solvents ofthe nitrocellulose lacquer as the same dries. For thispurpose I have illustrated a pipe 7 leadingto a suction fan 8 which may discharge into any suitable conclosed room 9 which may be maintained at a5 temperature most conducive to the securing of satisfactory results. I have indicated cooling coils 11 in the room so that the atmos-v phere about the machine may be cooled to the extent desired; In practice the atmosphere will be kept at a temperature of approximate 1y 60 F.

For the purpose of maintaining an atmosphere about the machine itself which is highly saturated with solvents, a wall 12 is preferably built around the machine to a height slightly above the highest point of travel of the printing blocks. The solvent vapors which are heavier than air, will be confined in this enclosure so that a highly saturated atmosphere will exist around the printing blocks. This will practically eliminate evapK oration of the lacquer on the block, so that the block will not become choked. At the same time the enclosure Will not interfere .with Workmen in their operation of the machine.

By maintaining a low temperature and a solvent saturated atmosphere about the niachine, practical operation with nitrocellulose lacquers can be carried on.

The materials which may be used will consist of a solution of nitrocellulose in suitable solvents, together with plasticizers or softeners, gums or resins, any desired pigments or fillers to produce the right shade= and any non-solvents for nitrocellulose which are volatile and which may be used either cheap thinners or a solvents for the resins.

The nitrocellulose will be the soluble form of the product of nitration of cellulose, of which cotton is the usual source. It is preferably of a type which forms solutions of lowviscosity.

The solvents may be any of the materials l that dissolve or disperse nitrocellulose. These may be alcohols, ethers, esters, ketones, aldehydes, or any combinations of these substances, and may fall into any or all of the classes commonly known as low, medium, or high boiling solvents.

Among the batter known substances now in use are methyl, ethyl, butyl, amyl, and the higher alcohols, which may be monohydric,

.di-hydric or higher; acetone, ethyl methyl ketone, or any of the higher ketones including the ketone alcohols, such as diacetone alcohol; the acetates, butyrates, proprionates, lactates, phthalates, carbonates, or other esters of methyl, ethyl, butyl, amyl, or other alcohols. Certain other compounds such as some aldehydes, so-called oxides, and camphor might also be used, but it is to be understood that the invention is not limited to any of these specific solvents mentioned.

The plasticizers or softeners may be any of the common vegetable oils such as rape, castor, linseed, china wood, perilla, or other non-drying, semi-drying, or drying fatty oils; the phosphates of organic radicals such as the dior triphenyl or cresyl phosphates; the stearates, tartrates, phthalates, lactates or other non-volatile softening materials soluble in the nitrocellulose solvents and being preferably, but not necessarily, solvents Ifor nitrocellulose. Resins may or may not be used, depending on the type of paint or sur-V face desired. Examples of such materials which can be used are rosin, ester gum, shellac, dammar, gilsonite, manila or pontianak, any of the copals, or various synthetic resins.

The pigments which are used may be any of the pigments now commonly used in paints or other decorative coatings, such as lithopone, zinc oxide, titanium oxide, oxides of iron, Prussian or ultramarine blues, chrome or iron yellows and greens, any of the forms of carbon black, and any of the lake colors.

Non-solvents may or may not be used as diluents or as solvents for the resins. Some of these non-solvents are hydrocarbons of the aliphatic or aromatic series, or certain alcohols which alone have little or no solvent action on nitrocellulose.

Where the oils mentioned are used as the plasticizers, the preferred method is to grind the pigment in all or part of this oil. The paste Which results is then mixed in the previously prepared .nitrocellulose solution, which may also contain the remaining part of th'e plasticizer, if any, and the resin. The paint is then thinned for use with any of the above solvents or non-solvents, or combinations thereof.

Another procedure which has been found satisfactory in all cases, but especially so where solid plasticizers are used, consists of mixing all the ingredients in a closed container, such as a ball or pebble mill. This method may be varied somewhat by dissolving the nitrocellulose and resin separately in suitable solvents, the two solutionsl then being mixed with plasticizers and the entire mixture being ground with the pigment as above suggested. The thinning to printing consistency is then done as before described.

From the foregoing it will be seen that there is a very wide choice of materials possible and thenumber of variations in composition is almost infinite. It has been found, however, that where the composition is to be used on printing blocks in a normal atmosphere, that it is necessary to use a large proportion of the high boiling point sol- Femelle #1 ment ground in this solution. The remainder of the gum is dissolved in a portion of the diacetone alcohol which is used for thinning. The pa'ste'of pigment, butyl phthalate, gum Solution and diacetone gum solution are all thoroughly mixed and then thinned to printing consistency.

After any of the above compositions have been made they are then applied to the printing blocks, which may be either hand manipulated blocks, or be machine operated blocks, as hereinbefore described and applied to suitably prepared linoleum, felt base, or other# hard surfaced floor covering material. As many different colors may be applied as are desired, and the paints may be applied either toa rug design or to a continuous design. The operation of printing is substantially the same as that carried out with the present oil paints except that the machine is preferably enclosed in order to reduce evaporation of the low boilingsolvents and thereby prevent a clogging of the printing blocks. By reference to igure 2, it will be readily seen that Parte the blocks might easily become clogged if N itrocellulose solution (20 oz. nitrocelcare is not taken to prevent evaporation of lulose to gallon of ethyl acetate) 100 the solvents. Y Castor oil 50 Tie plgment may be applied to the print- Pigment ing loc sin any of the usual ways, the draw- A i howinfr reci rocati ots of the usual Grind p1gment separately 1n a portlon of mg s s p ng p thecastor oil, mix all ingredients and thin to dfl thls purpose' The Pots are deslg" gg alltlglcy Wlth equal parts butyl Ihe drying of the pattern after it has been printed is done either at normal or elevated Fam/ula #2 P temperatures, as hereinbeore described. The arts 1 N itrocellulose solution (asin #1) 125 lsillln egg lgglitli'goeg 153; lllllh-al-t ustratdieans flor withdrawing the vapors romt e yingc amber. Plgmml' 60 The evaporatioi of the solvent 'and the con- The ester gum -is'djssolved in the butyl sequent setting o the nitrocellulose both on phthalate and the pigment ground in this the. goods and on the printing blocks is resolution; ell ingredients are then mixed and ardldt Consldetrebly 'by nlntauim a rethe whole is thinned to proper consistency UC@ empelii Ure aIOllIl il e Pllntmg al)- with diacetone alcohol and toluol. lal'atus, 3S Well as by Operatlng the machine Fomula #3 1n Ia solvent laden atmosphere.

am aware of the fact that nitrocellulose Ntroceuulose Solution (as in #1) Pt lacquers and paints are at the present time T pheny1 Phosphate 30 well known, and that 1t has been proposed-t0 Manila 15 apply slch lacquersf and paints to Hoor cov- Pigment erlngs y means o sprays or brushes, but

- heretofore l f I w The Manila gpm iS dissolved `Separately has been dtseiieliieiils byuilnzalilsrednowlhiglciesz ln a Smau q uantlty 0f Qthyl ,alcOhQl and au lacquer'can be appliedto a floor covering in lng? @1d-lent? algfound 1n 9- bflu mln finally a commercially practlcal manner by means of Wlth la-Ctate, 3.1001101, and a block process toluol. Fwmuza #4 oIlf( dsired, lair op coaltlpglof clear laccuer c u e app e over e aoquer pain to P. rts Lacquer (20 oz. ethyl acetate solution) l20 aford .protectlon thereto' Butyl phthalate 2O An important advantage 1n the use of a Ester um 30 lacquer paint 1s the fact that it dries quick- Pigmlt. i' 60 1y, ehminating some of the present curing "T time, so that less space in the curin Chamg About five parts of the ester gum are clisbers or stoves 1s requlred.` A further imsolved 1n the butyl phthalate and the plg- .portant advantage is that the printed colored llU pattern is more resistant to alkaline .soa-ps' and cleansers than is an oil paint.

While I have described and shown certain methods and apparatus for carrying out the invention, it will be understood that the inveiition is not restricted to the particular methods and apparatus disclosed, these being merely illustrative of the spirit of my invention, and various changes and modifications may be made therein within the scope and contemplation of my broader claims.

- I claim:

` l. The method of applying lacquer paint to a floor covering which consists in applying the paint first to a printing block, and pressing the printing block against the Hoor covering while maintaining an atmosphere about the printing block which precludes any substantial evaporation of the lacquer solvents on the printing block.

2. The method of applying pigment bearing nitrocellulose lacquer containing low boiling point solvents to fioor cove-rings which consists in applying the lacquer to printing blocks, pressing the'printing blocks against the iioor covering, and maintaining an atmosphere about the printing blocks saturated with the low boiling point solvents whereby any appreciable evaporation of the solvents from the lacquer applied t0 the printing blocks is precluded.

3. The method of applying lacquer paint to floor coverings in a block printing machine which consists in operating the machine in an atmosphere which precludes evaporation of the solvents of the lacquer paint during the printing process.

4. The method of applying lacquer paints to a Hooi covering by means of a block printing machine which consists in maintaining an atmosphere around the machine which is saturated with solvents contained in the lacquer paint whereby any choking of the printing blocks with the paint is avoided.

5. The method of printing a multi-colored pattern on a floor covering materialwith a lacquer paint which consists in passing the floor covering material under a series of printing blocks arranged to applyhdifferent colored lacquer paints thereto While maintaining the material and the printing blocks in an Yatmosphere which substantially precludes evaporation of the solvents from the lacquer, whereby the printing blocks are prevented from becoming choked with the lacquer paint, and subsequently exposing the printed material to an atmosphere conducive to the evaporation of the solvents.

G. The method of surfacing ioor covering materials which consists iii applying lacquer paint to the surface of the material by means of printing blocks under conditions which preclude any substantial evaporation of the solvents from the lacquer paint, and then curing the paint in an atmosphere coniducive to the rapid evaporation of the solvents therefrom. f

7. The method of surfacing floor covering materials with lacquer paint which consists in applying the paint to the material in a block printing machine, maintaining an atmosphere about the machine saturated with solvents fromvthe lacquer paint, then introducing the product to a curing chamber, and withdrawing the vapors of the solvents from the curing chamber to facilitate the rapid removal thereof.

8. Apparatus for 'applying lacquer paint to floor coverings comprising a block printing machine and an enclosing casing therefor by means of which an atmosphere may be maintained about the machine which precludes the evaporation of the solvents from the lacquer paint.

9. Apparatus for applying lacquer paint to the surface of floor coverings comprising a block printing machine, an enclosing housing there-foi' in which a saturated atmosphere can bemaintained, a curing chamber to which the printing machine delivers, and

means for withdrawing vapors from the euring chamber.

10. The method of applying lacquer paints to floor coverings which consists in applying the paint to a printing surface and then pressing the surface against the iioor covering while maintaining an atmosphere of reduced temperature saturated with solvents from the lacquer about the printing surface.

1l. The method of applying lacquer paints to afloor covering by means of a block printing machine which consists in maintaining an atmosphere around the machine which is saturated with solvents contained in the A lacquer paint whereby any choking of the i' printing blocks with the paint is avoided, and while maintaining such atmosphere at a reduced temperature.

l2. Apparatus for applying lacquer paint to floor coverings comprising a block printing machine and an enclosing casing therefor by .means of which an atmosphere may be maintained about the machine which precludes the evaporation of the solvents from the lacquer paint, and means for cooling the atmosphere about the machine.

13. Apparatus for applying lacquer paint to floor coverings including a block printing machine. an enclosure around the sides of the machine open at its top, a room in li".

l5. The method of applying lacquer paints to a floor covering which comprises applying 'the paint to the material in a block printing v machine, the paint having a solvent, trapping the evaporated solvent, maintaining it in the atmosphere surrounding the machlne, and controlling the?l temperature of the solvent-laden atmosphere.

16. The method of applying lacquer paints to a floor covering whichA comprises applying the paint to the material in ablock printing machine, the paint having a solvent, trapping the evaporated solvent, maintaining it in the atmosphere surrounding the machine, and cooling the solvent-laden atmosphere.

17. The method of applying lacquer paints to a floor. covering which comprises supplying paint in a solvent to a'block printing machine for the application thereof to the material, and blocking escape of evaporated solvent around the sides of the machine to a height above that of the printing surfaces.

18. Apparatus for applying lacquer paint to floor coverings comprising a block print.- ing machine and an enclosure therefor, said enclosure being arranged so that the material to be printed travels therethrough.

In testimonyT whereof l have hereunto set my hand.

ALFRED JONES. 

